Clinical Evaluation of Torque Protocols on the Stability of 3D-Printed Anatomical Healing Abutments

(1) Background: Customized 3D-printed anatomical healing abutments (AHAs) are increasingly incorporated into digital implant workflows to optimize emergence profile development. However, the influence of tightening torque on their mechanical stability remains poorly understood. This prospective pilot clinical study evaluated the effect of different torque protocols on the stability of 3D-printed AHA placed on intermediate abutments. (2) Materials and Methods: Forty-two patients (52.4 ± 12.3 years) receiving 60 Paltop implants (Paltop Advanced Dental Solutions Ltd., Ashkelon, Israel) were included. Following implant uncovering, all implants received titanium intermediate abutments fabricated from a photopolymerized acrylate-based resin (MAZIC D TEMP; Vericom Co., Ltd., Chuncheon, Republic of Korea), torqued to 35 Ncm, and were allocated to four AHA tightening protocols. Clinical mobility, torque maintenance, and mechanical complications were evaluated at 4, 8, and 12 weeks. Group comparisons were performed using Fisher’s exact test. (3) Results: At 12 weeks, mobility occurred in 5/15 AHA (33.3%) in the hand-tightened group and 1/15 AHA (6.7%) in the 20 Ncm group, whereas no mobility was observed in 15/15 AHA (100%) in both the 25 Ncm and 30 Ncm groups. Mechanical complications differed significantly among groups (Fisher’s exact test, p = 0.047). (4) Conclusions: Tightening torques ≥ 25 Ncm provided superior early mechanical stability of 3D-printed AHA.